hs-fcc for propylene: concept to commercial operation · 42 ptq q1 2014 maximum gasoline yield is...

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HS-FCC for propylene: concept to commercial operation T he fluid catalytic cracking (FCC) process has undergone a long evolution of hardware and catalyst changes, from bed cracking with amorphous catalyst to short contact time riser cracking with sophisticated zeolite catalyst systems. Improvements to the process have provided a wide degree of flexibility to selectively target the production of distillates or gasoline, or propylene from VGO and residue feeds, thereby making FCC the most widely used conversion process. More generally, the objective of the process is to produce high valued products, and increasingly this includes fuels and petrochemi- cals, such as light olefins and aromatics. At present, over 30% of the worldwide propylene supply comes from FCC-related processes (FCC, RFCC, DCC). Fluctuating product demand and price have caused most new project develop- ers to demand product flexibility for long-term profitability and process integration with petro- chemical facilities for added synergy and cost savings. In order to respond to these market demands, a new high sever- ity down flow FCC (HS-FCC) process has been developed by an alliance of Saudi Aramco, JX Nippon Oil & Energy (JX) and King Fahd University of Petroleum and Minerals (KFUPM), culminating in a 3000 b/d semi-commercial unit in operation since 2011 in Japan (see Figure 1). The process provides a high light olefin yield from a wide variety of feedstocks utilising high severity reaction conditions, a novel down flow reaction system and A FCC process provides a high light olefin yield from a wide variety of feedstocks utilising high severity reaction conditions and a novel down flow reaction system NICOLAS LAMBERT Axens IWAO OGASAWARA JX Nippon Oil & Energy IBRAHIM ABBA Saudi Aramco HALIM REDHWI King Fahd University of Petroleum & Minerals CHRIS SANTNER Technip Stone & Webster Process Technology proprietary catalyst. HS-FCC is now available for licence from a Global Alliance by Axens and Technip Stone & Webster Process Technology. Features of HS-FCC FCC utilises acidic zeolite catalysts to crack heavy hydrocarbons into lighter fuels such as gasoline and distillate and, under more severe conditions, into lighter olefins such as propylene and butylene (and, to a lesser extent, ethylene). Complex secondary reactions that can degrade the primary products to less valuable components should be limited to retain product selectivity and refinery profitability. For HS-FCC, the objective is to not only improve the selectivity for normal fuels production, but also to maximise the potential of light olefin and petrochemical produc- tion at high severity. HS-FCC provides a total system to maximise product selectivity and, in particu- lar, propylene yield. Three key elements are required to attain this objective: www.eptq.com PTQ Q1 2014 39 Figure 1 HS-FCC semi-commercial unit

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Page 1: HS-FCC for propylene: concept to commercial operation · 42 PTQ Q1 2014 maximum gasoline yield is about 5 wt% higher in the down flow system. When olefins are of inter-est, the more

HS-FCC for propylene: concept to commercial operation

The fluid catalytic cracking (FCC) process has undergone a long evolution of hardware

and catalyst changes, from bed cracking with amorphous catalyst to short contact time riser cracking with sophisticated zeolite catalyst systems. Improvements to the process have provided a wide degree of flexibility to selectively target the production of distillates or gasoline, or propylene from VGO and residue feeds, thereby making FCC the most widely used conversion process.

More generally, the objective of the process is to produce high valued products, and increasingly this includes fuels and petrochemi-cals, such as light olefins and aromatics. At present, over 30% of the worldwide propylene supply comes from FCC-related processes (FCC, RFCC, DCC). Fluctuating product demand and price have caused most new project develop-ers to demand product flexibility for long-term profitability and process integration with petro-chemical facilities for added synergy and cost savings.

In order to respond to these market demands, a new high sever-ity down flow FCC (HS-FCC) process has been developed by an alliance of Saudi Aramco, JX Nippon Oil & Energy (JX) and King Fahd University of Petroleum and Minerals (KFUPM), culminating in a 3000 b/d semi-commercial unit in operation since 2011 in Japan (see Figure 1). The process provides a high light olefin yield from a wide variety of feedstocks utilising high severity reaction conditions, a novel down flow reaction system and

A FCC process provides a high light olefin yield from a wide variety of feedstocks utilising high severity reaction conditions and a novel down flow reaction system

NICOLAS LAMBERT Axens IWAO OGASAWARA JX Nippon Oil & Energy IBRAHIM ABBA Saudi Aramco HALIM REDHWI King Fahd University of Petroleum & MineralsCHRIS SANTNER Technip Stone & Webster Process Technology

proprietary catalyst. HS-FCC is now available for licence from a Global Alliance by Axens and Technip Stone & Webster Process Technology.

Features of HS-FCCFCC utilises acidic zeolite catalysts to crack heavy hydrocarbons into lighter fuels such as gasoline and distillate and, under more severe conditions, into lighter olefins such as propylene and butylene (and, to a lesser extent, ethylene). Complex secondary reactions that can

degrade the primary products to less valuable components should be limited to retain product selectivity and refinery profitability. For HS-FCC, the objective is to not only improve the selectivity for normal fuels production, but also to maximise the potential of light olefin and petrochemical produc-tion at high severity. HS-FCC provides a total system to maximise product selectivity and, in particu-lar, propylene yield. Three key elements are required to attain this objective:

www.eptq.com PTQ Q1 2014 39

Figure 1 HS-FCC semi-commercial unit

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40 PTQ Q1 2014 www.eptq.com

products and parallel bi-molecular hydrogen transfer reactions leading to paraffin formation and aromisa-tion of naphthenes. Managing the acid site density of the catalyst can suppress hydrogen transfer and isomerisation reactions to maximise olefins production. When coupled with ZSM-5 pentasil cracking cata-lyst additives, the increased olefins in the gasoline cut can be selec-tively cracked to further increase the propylene yield.

The HS-FCC catalyst uses a high USY zeolite content system with very low acid site density, formu-lated to minimise hydrogen transfer reactions for high olefin selectivity, and low coke and gas selectivity. This catalyst has been shown to be more effective for propylene production when coupled with ZSM-5 additives (see Figure 2). Commercial catalysts and HS-FCC catalyst exhibited a similar trend in gasoline and propylene yield as a function of conversion (severity), but the customised HS-FCC catalyst was much more effective in ‘feed-ing’ the ZSM-5 additive with more olefins, and more accessible linear olefins, to produce more propylene.1

Optimised reaction conditionsWhen targeting maximum petro-chemicals production, HS-FCC operates under more severe condi-tions than conventional FCC. The main reaction conditions applied and the advantages and challenges presented are shown in Table 1.

High reaction temperature coupled with short contact time increases the primary reactions towards olefins, while limiting the unwanted secondary reactions of hydrogen transfer and thermal degradation. A consequence of the increased severity and short time is the need for higher catalyst circula-tion (catalyst-to-oil mass ratio, or

• Highly selective catalyst and additive system• Optimised reaction conditions• Down flow, short contact time reaction system with rapid catalyst separation.

The balance of these elements

and realisation at commercial scale is the key to success.

Catalyst systemThe catalytic cracking reaction pathways are complex, with the primary formation of olefinic

75 80 85 90

Conversion, mass%

75 80 85 90

Conversion, mass%

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+10% ZSM-5 additive+10% ZSM-5 additive

+10% ZSM-5 additive

HS-FCC catalyst

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Figure 2 Proprietary catalyst boosts ZSM-5 effectiveness for more propylene

Advantages ChallengesHigh temperature High conversion and olefins selectivity Increased thermal cracking, product degradation

Short contact time Reduced secondary reactions and Reduced conversion, rapid mixing thermal cracking and separation required

High catalyst/oil Increased catalytic cracking Very high catalyst circulation, uniform flow, mixing and separation

Reaction conditions and advantages of HS-FCC in petrochemicals production

Table 1

FCC HS-FCCReaction T,°C 500-550 550–650Contact time, s 2–5 0.5–1.0Catalyst/oil, wt/wt 5-8 20–40Reactor flow Up flow Down flow

Typical operating conditions for FCC and HS-FCC

Table 2

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www.eptq.com PTQ Q1 2014 41

C/O) to provide the required heat to the reactor and sufficient catalyst activity to achieve high conversion at short contact time. The range of operating conditions for a conven-tional FCC and HS-FCC are summarised in Table 2.

Down flow reaction (DFR) system The specific reaction conditions with very high C/O result in certain challenges in a conventional

up flow FCC riser reactor system, where the catalyst required for the reaction is lifted up the reactor pipe or riser by the vaporised and cracked hydrocarbon feed. In up flow fluid-solid systems, the solids or catalyst are conveyed upwards against the force of gravity by drag forces from the rising gases (hydro-carbons). As a result, all riser reactor systems have varying degrees of catalyst back-mixing and

FCC up flow riser

Reactor residence time

Low conversion

HS-FCC down flow

Over cracking

Back mixing

Feed + catalyst

Plug flow

Feed + catalyst

Figure 3 Up flow vs down flow residence time profiles

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Conversion, wt%

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Figure 4 Selectivity benefits of a down flow reaction system4

Table 2

scan points representing one as-built pipe. Evidently, that is only one clash, but some systems will register it as thousands of clashes, making it diffi cult to identify the real clash and to resolve it effectively.

Ensuring that an accurately designed pipe spool actually fi ts correctly on site requires accurate fabrication. Leading 3D design solutions such as our PDMS or AVEVA Everything3D can not only generate fully detailed fabrication drawings automatically, they can also perform manufacturability checks at the design stage to help maximise fabrication quality. It is also now possible to scan a completed fabrication and compare it against the design model, to quickly verify its accuracy and resolve any errors early.

Owner-operators considering placing revamp projects should review a contractor’s capabilities in these areas. The most capable typi-cally achieve less than 1% design-related rework costs, even on complex projects. Our vision of plant design for lean construction goes further than this; our goal is to use laser scanning, among other tools, to completely eliminate rework in construction. This vision is discussed further in a business paper.2

Plan the installationScheduling the revamp installation involves similar considerations to planning the original survey. EPCs and owner-operators must collabo-rate closely to achieve a well-executed installation. Here, the power of 3D design can add considerable value.

Reverse engineering objects that are to be removed enables the crea-tion of accurate demolition drawings and the determination of weight and centre of gravity, which informs the correct use of handling equipment. Model animation enables planners to evaluate proposed task sequences and to check that, for example, items can be moved safely in the available space constraints. Design review is arguably even more important for revamps than for new-build

www.eptq.com Revamps 2013 31

projects; revamps take place on plants that may contain hazardous chemicals, temperatures or pressures. Evidently, these consid-erations imply the need for well-specifi ed, specialist plant design software.

Business processThe introduction to this article referred to the need for effi cient business processes. That is hardly a great insight, but, in the engineer-ing industry, business processes are inextricably linked with the engi-neering and design technologies that generate project information. Best practice is therefore to select solutions that can share informa-tion effi ciently and reliably. An effi cient revamp project workfl ow can thus be achieved using 3D design technology that integrates both with laser scan data sources and with engineering data sources, so that engineering and design information can be kept synchro-nised as the project progresses. From this, new design can automat-ically generate accurate materials requirements that feed into an enterprise resource management (ERM) system.

Such engineering, design and information management technolo-gies now exist and are in use on a wide variety of new-build projects. Their ability to support effi cient business processes becomes even more important on revamp projects with their need for on-time, right-fi rst-time, low-risk installation.

References1 Lighting the Way, www.aveva.com/publications2 Plant Design for Lean Construction: Innovation for a new era in plant design, www.aveva.com/publications

Gary Farrow is Vice President 3D Data Capture with AVEVA in Cambridge, UK. He works with customers in the use of 3D data capture technology to increase productivity and to advance the performance of AVEVA’s LFM software. A mechanical engineer, he has been involved in 3D laser scanning from its inception in the late 1990s, initially undertaking projects delivering data and 3D models, including a huge scanning project for Fluor/TCO in Kazakhstan.

I think I’ve got liquid carryover.what can I do about it?

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It happens in petrochemicalplants, refineries, and anywhereelse that the gas approaching a compressor is wet. Traces ofaqueous or organic liquid escapethe inlet knockout drum, oftenintermittently, and silently damag-ing the compressor. Telltale signsinclude pitting corrosion, saltdeposits, and diluted lubricants.

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AMACSCompressor suction drums:

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Instead of trying to repairsymptoms, look for the root cause,which usually involves the misteliminator in the knockout drum.Problems may include impropermist eliminator specifications,overloading, uneven velocity, waxydeposits, liquid slugs, foaming,incorrect installation, and severalother possibilities. New, high-capacity, high-efficiency mist eliminator technologies pay off thefirst time you avoid shutdown.

rev aveva.indd 3 10/09/2013 11:20

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42 PTQ Q1 2014 www.eptq.com

maximum gasoline yield is about 5 wt% higher in the down flow system. When olefins are of inter-est, the more selective down flow reaction environment can produce substantially more light olefins (C2-C4) at the same gasoline yield compared to a conventional up flow system (see Figure 4b).

Although the idea of a controlled high severity, short contact time down flow reaction has been considered for some time, achieving this successfully on a commercial scale has been elusive. Extensive

plug flow reaction conditions, as summarised by Cheng.2 When plug flow conditions are achieved, more selective primary cracking results in greater selectivity. FCC pilot work demonstrating the effects of short contact time and down flow have been reported by Del Poso3 and Abul-Hamayel4 (see Figures 4a and 4b). The general trend is that of greater gasoline selectivity at short contact time down flow, with a maximum yield achieved at a higher conversion level. This effect is seen in Figure 4a, where the

reflux along the walls, particularly in the feed injection or catalyst pick-up zone at the bottom of the riser reactor. At very high C/O, significant back-mixing is unavoid-able. This problem is overcome in a down flow reactor (DFR), where both the catalyst and feed flow downwards together (see Figure 3).

Down flow fluid-solid reaction systems have been of increasing interest in recent years to achieve

Figure 5 HS-FCC demonstration unit

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Bench scale (0.1 bpd) Demo plant (30 bpd)

Propylene 10.5%

Propylene 10.6%

RON 98

RON 99

Figure 6 Bench scale vs demonstration scale results on low sulphur VGO at high severity without ZSM-5

Lift air

Main air

Air outlet

Catalyst circuit

Air outlet

Catalytic circulation hopper

Catalytic circulation hopper

Injector

Separator

Total height: 35m (115ft)

Catalyst inventory: 20T

Max. catalyst circulation: 1.0T/min

Figure 7 500 b/d equivalent cold flow testing to scale up and optimise the reaction system

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www.eptq.com PTQ Q1 2014 43

obtained along with a very high octane gasoline.

Work immediately began on scale-up to a commercial unit. Important lessons were learned concerning equipment design, and larger-scale cold flow work was undertaken by JX in Japan at the 500 b/d equivalent scale to opti-mise the feed injection zone and separator design (see Figure 7). This work was coupled with CFD simulations to assist in larger-scale equipment design.6

Semi-commercial unitWith the successful demonstration of HS-FCC technology at the 30

catalyst circulation loop and reactor-separator equipment to validate the design of the demon-stration unit.

The demonstration unit (see Figure 5) was operated from 2003-2004 at the Aramco Ras Tanura refinery. Results from the demon-stration unit validated the HS-FCC concept, with good agreement between 0.1 b/d pilot results and 30 b/d demonstration (see Figure 6).5, 6

A low sulphur VGO was cracked at high severity in both the pilot and demonstration units using only the new HS-FCC catalyst without ZSM-5 additive. A very high propylene yield, over 10%, was

pilot work at the 0.1 b/d scale demonstrated the principle, catalyst system and operating conditions, but did not address how rapid mixing, reaction and efficient cata-lyst/gas separation can be achieved at a large scale with a target resi-dence time on the order of 0.5 seconds. On a commercial scale, equipment design for very short contact time with the mechanical integrity to withstand high-velocity catalyst circulation in a coking envi-ronment requires extensive research, development and demonstration.

R&D historyThe challenges of developing this new technology required a systematic research program under-taken by JX, KFUPM & Saudi Aramco with the support of Japan Cooperation Center, Petroleum (JCCP). Early pilot work by both JX and KFUPM in 1996-2000 demon-strated the benefits of high severity operation at controlled short contact time in down flow mode. Aramco became an active partici-pant in the scale-up effort to design a 30 b/d demonstration unit. JX conducted large-scale, 30 b/d equivalent, cold flow testing of the

VGO + HDT VGO + VGO+ HC Btm VGO DAO ARFeed SG 0.845 0.879 0.891 0.915Reactor T, ºC 575 595 580 600Conv, w% 93.2 83.7 83.0 82.4Light olefins, wt% 39 34 31 31C

2= 4 4 3 3

C3= 19 17 15 15

C4= 16 13 13 12

C5-220 gasoline, wt% 35 34 34 34

RON 98.5 98.1 98.1 98.4

Semi-commercial unit performance

Table 3

Feed Feed

Product

Quench

Catalyst

Catalyst

Injectors

Separator

CFD simulation

Combined kinetic and hydrodynamic model

27 lump kinetic model

DFR (down flow

reactor)

Assembly of a large number of small reactors

Feed Catalyst

Product

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Feed CFeed D

Figure 8 Combined kinetic and hydrodynamic modelling assists design and scale-up

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44 PTQ Q1 2014 www.eptq.com

produced becomes a significant boost to the economics. The gaso-line also has value beyond fuels, with an octane of 98-99, olefin content of 25-40 wt% and 35-50 wt% aromatics.

The testing programme will continue, with 100% residue crack-ing trials to begin soon. With a controlled short contact time, high C/O and p lug flow reaction system, HS-FCC is well adapted to be highly selective for both light and residue feed conversion to petrochemicals.

Throughout the programme, equipment evaluation, inspection and reliability data continue to be gathered to guide further develop-ment and scale-up to a fully commercial scale of at least 30 000 b/d. In parallel to this work, CFD simulation of the DFR and separator hydrodynamics are being combined with a kinetic model to analyse the results, validate the kinetic models, and enable accurate predictions at commercial scale for future feeds and reactor configurations.

HS-FCC in the family of catalyticcracking processesThe HS-FCC process expands the operating window of catalytic crack-ing to encompass heavier feeds and greater propylene potential. Commercial processes for high propylene production from light distillate feeds and residue feeds include DCC,8 high-propylene FCC (HP FCC) and resid to propylene (R2P). More severe conditions for residue feeds to attain a higher propylene yield have proven chal-lenging in the past due to undesired secondary reactions. High severity, combined with an optimised cata-lyst system and a controlled short contact time DFR reaction system, allows the new HS-FCC technology to provide selective conversion with lower fuel gas production and a greater olefin and petrochemicals yield even with heavy residue feeds. Indeed, the selectivity of the system presents opportunities to crack a wide range of conventional and unconventional feedstocks.

The technology mapping by severity and feedstock is shown in Figure 9.

evaluate yields and product proper-ties for widely different feeds and to demonstrate equipment reliabil-ity. Preliminary results showing yields for several blends of VGO, hydrocracker (HC) bottoms, DAO and atmospheric residue are shown in Table 3. Combined light olefin (C2-C4) yields of 30-40 wt% have been demonstrated with 15-19 wt% propylene and 4 wt% ethylene. The yield of butenes is similar to propyl-ene and offers opportunities for greater petrochemical integration, including oligomerisation and the FlexEne configuration for even higher propylene production.7 These results are without the use of post-separator quench injection, which will improve olefin selectiv-ity further. The catalyst system continues to be optimised for the various feeds.

When viewed from a petrochemi-cals perspective, the ethylene

b/d scale completed, it was time to look forward to scaling up to a full-sized commercial unit and to plan for future licensing of the technol-ogy. Several FCC licensors were interviewed and evaluated before Axens and Technip Stone & Webster Process Technology were selected to assist in the design of a 3000 b/d semi-commercial unit, plan for a larger commercial unit, and serve as exclusive licensor for the HS-FCC technology, relying on its extensive knowledge in FCC and RFCC design.

A complete 3000 b/d HS-FCC unit with main fractionator, gas plant and flue gas treatment was designed for the JX Mizushima refinery. Chiyoda Engineering performed the detailed engineering and construction of the plant (see Figure 1), which was put on stream in early 2011.

Performance trials are on-going to

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Figure 9 Family of high-propylene catalytic cracking processes

HS-FCCOligomerisation

Polynaphtha

PRU

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Aromatics complex Paramax

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Polymer grade ethylene

Polymer grade propylene

Bz + PX + OX

Fuels

HS-FCC unit Petrochemicals

Figure 10 Integrated refinery-petrochemical complex

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www.eptq.com PTQ Q1 2014 45

8 Dharia D, Increase light olefins production, Hydrocarbon Processing, April 2004.9 Roux R, Upgrading of heavy cuts into max olefins through HS-FCC, JPI Petroleum Refining Conference, Tokyo, 2012 and www.axens.net.

Nicolas Lambert is Technologist in Axens’ Middle Distillates & Conversion Business Line, focusing on FCC technology. He is a graduate of Arts & Métiers ParisTech.Iwao Ogasawara is Facility Planner of Technical & Engineering Service Department, Refining Technology & Engineering Division, JX Nippon Oil & Energy Corporation. He holds BS and MS degrees in chemical engineering.Ibrahim A Abba is Chief Technologist of the Chemicals Research Division of Saudi Aramco Research & Development Center. He holds a PhD from the University of British Columbia.Halim Redhwi is the CEO (A) of Dhahran Techno-Valley Company and a Professor in the Chemical Engineering Department, King Fahd University of Petroleum & Minerals, Saudi Arabia. He holds BS, MS, and PhD degrees in chemical engineering.Chris Santner is Senior Director of Catalytic Cracking Refining Technology with Technip Stone & Webster Process Technology. He holds BS and MS degrees in chemical engineering from the University of Houston.

Technip Stone & Webster Process Technology are now offering HS-FCC technology on behalf of the HS-FCC Global Alliance team.

FlexEne is a mark of Axens.

References1 Maghrabi A, HS-FCC process for maximized propylene production, 10th Annual Saudi-Japanese Symposium on Catalysis in Petroleum Refining and Petrochemicals, Dhahran, 2000.2 Cheng Y, Downer reactor: from fundamental study to industrial application, Powder Technology, 183, 2008.3 Del Poso M, Development of ultra selective cracking technology, 2nd IFP and S&W FCC Forum, The Woodlands, Texas, 1996. 4 Abul-Hamayel M A, Comparison of downer and riser based fluid catalytic cracking process at high severity conditions: a pilot plant study, Petroleum Science Technology, 22, 2004.5 Redhwi H, Meeting olefins demand in a novel FCC technology, 18th World Petroleum Congress, South Africa, 2005.6 Okazaki H, High severity Fluidized Catalytic Cracking (HS-FCC) – go for propylene!, 20th World Petroleum Congress, Doha, 2011.7 Ross J, (R)FCC product flexibility with FlexEne, WRA Downstream Asia, Singapore, 2011 and www.axens.net.

With the option to operate at conventional severity or high sever-ity, the refiner will have the ability to select an operating mode and feedstock best suited to the prevail-ing economic conditions. A high severity product slate rich in olefins and aromatics also makes integra-tion with petrochemicals plants more attractive so that the natural synergy of shared intermediate products and recovery schemes can be realised.9 An example of HS-FCC integration with a petrochemical complex is shown in Figure 10.

Global Alliance for commercialisationThe HS-FCC technology is the product of systematic process research, catalyst development, pilot work, 30 b/d demonstration unit testing, and ongoing semi- commercial operation and testing at the 3000 b/d scale. These successful results and the modelling tools developed for further scale-up make the technology ready for commercialisation. Axens and

www.eptq.com PTQ Q4 2013 97

technology, as the worldwide industrial standard for clean syngas production, it provides a clean hydrogen product and enables economic carbon capture.Lurgi Rectisol, MPG, OxyClaus and Purisol are marks of Air Liquide Global E&C Solutions (Lurgi GmbH). Selexol is a mark of UOP, a Honeywell company.

Max-Michael Weiss is Director Innovation, Clean Conversion, with Air Liquide Global E&C Solutions/Lurgi GmbH. He graduated as Diplom Chemie Ingenieur (chemical engineering) from the Technical University of Karlsruhe, Germany. Helmut Heurich is Director for Refinery Applications in the HyCO Product Line in Global Engineering & Construction Solutions of Air Liquide. He studied process technology at the Technical University of Braunschweig.Delphine Roma is the Global Marketing Manager in charge of the refining industry within Air Liquide Global E&C Solutions. She holds an MSc and engineering degree from the École des Ponts et Chaussées in Paris.Stefan Walter is Head of Department, Gasification Technologies, with Air Liquide Global E&C Solutions/Lurgi GmbH. He graduated as Diplom Verfahrensingenieur (process engineering) from the Technical University of Aachen, Germany.

also integrated solutions for steam/energy generation and CO2 handling. Air Liquide can also provide an (over-the-fence) supply of air gases, power and steam, CO2 compression/liquefaction and transportation.

ConclusionIn the context of ever more stringent environmental regulations for refin-ers, there is a trend to increase residue conversion with hydrocrack-ers. Depending on the conversion rate of the units, the heavy bottom yield will range from 10-20%. Using Air Liquide Global E&C Solutions’ Lurgi MPG technology-based hydrogen production allows a refiner to transform these residues into an amount of hydrogen that balances the refinery’s needs.

MPG is a proven and reliable technology for securing the hydro-gen supply to a refinery. It further avoids the production of petroleum coke, and helps to consume much less natural gas and water. In combination with the Lurgi Rectisol

of most refinery off-gases, reduc-tion in natural gas and water consumption, and the recovery of CO2 for EOR or sequestration.

With the configuration shown in Figure 7, the feedstock to the MPG unit is normally reduced to that amount needed to satisfy the demand of the complex. If syngas production exceeds the amount needed to produce the required hydrogen (depending first of all on the crude quality/origin), the surplus syngas can be used for power generation with gas turbines or the production of chemicals/fuels. Air Liquide Global E&C Solutions can provide the applica-ble technologies (see Figure 7). Besides MPG technology, including air separation, CO shift, syngas cleaning, Lurgi Rectisol, PSA and methanation, the company also has technologies for sulphur recovery (preferably OxyClaus, since oxygen is available), technologies for chem-icals (such as methanol and propylene) and fuels production (for instance, Fischer-Tropsch), but

www.eptq.com PTQ Q3 2013 99

cracking reactions over the strictly thermal coking reactions that occur in the traditional delayed coker operation. During development, it has been observed that OptiFuel Technology shifts the delayed coker yields towards more valuable products, with reduced amounts of dry gas and coke.

Pilot plant verification Albemarle and OFTG have conducted a series of pilot plant runs at Penn State University (PSU). The scope of these studies has been to quantify the benefits of the tech-nology as a function of additive composition, feed properties and operating conditions.

vessels needed for additive mixing and storage.

The yield improvements seen with this technology are hypothesised to be the result of reactions in both the liquid and vapour phases, which are directly influenced by the additive. The active sites of the additive are intended to preferentially catalyse

Albemarle has designed an addi-tion system to ensure proper mixing of the solid and liquid portions and to avoid solids settling. The supply consists of a liquid carrier and the additive supplied to the refinery in bags or bulk shipments for mixing on-site. The additive injection system design minimises the size of

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3.00

1.42

–1.44

0.44

0.99

–1.57

–0.67

2.25

–2.28

0.43

1.85

–1.49

–0.30

1.79

Coke, %

C3 + liquid, %

Fuel gas, %

A2 A3 A4 B1 B2 B3 B4

Feed and formulation

Figure 3 Changes in pilot plant yields with application of OptiFuel Technology: pilot plant runs at Penn State University

Base PredictedCoke 32.2% 28.5%Dry gas 5.6% 4.4%C

3+ liquid yields 62.2% 67.1%

Projected yields for commercial application of OptiFuel Technology

Table 4

www.eptq.com PTQ Q2 2013 43

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Variante 4a

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2O

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Anton Alvarez-Majmutov is an NSERC Visiting Fellow at CanmetENERGY working on bitumen upgrading process modelling and simulation. He holds a PhD from Mexican Institute of Petroleum (IMP).

Jinwen Chen is a Senior Research Scientist and Group Leader at CanmetENERGY. He holds a PhD in chemical engineering from Tianjin University.

Mugurel Munteanu is a Lead Process Engineer at CoSyn Technology, a division of WorleyParsons, in Edmonton, Canada. He holds a PhD in chemical engineering from Laval University, Canada.

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